Tower Crane Operation Manual

Port said tunnels under Suez canal Project (PST) Date:10-7-2017
North tunnel ( Arab Contractors Company ACC) Revision: 00A

Technical office of site preparation administration Page 1 of 31
Project Port Said tunnels under Suez Canal.

Owner Engineering Authority For Egyptian Armed Forces.
Consultant SYSTRA & ECG Consultancy JV.
Main Contractor Arab Contractors & Orascom Construction JV.
Consultant SENER & AMBERG Consultancy JV.
Sub-Contractor Arab Contractors (Site preparation administration).
Document Name Operation instructions for tower cranes

Document Type Draft for Review.
00A 10/7/2017 Issued For Review

Rev. Date Description Pre. Ch.
North tunnel ( Arab Contractors Company ACC) Date:10-7-2017
Technical office of site preparation administration Revision: 00A
Operation instructions for tower cranes Page 2 of 31
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Table of Contents
1. Purpose ..........................................................................................................4
2. Scope of work ................................................................................................4
3. Definition .......................................................................................................4
4. References .....................................................................................................5
5. Execution strategy..........................................................................................6
6. Roles/responsibilities .....................................................................................6
7. Constrains during work ..................................................................................7
8. Safety .............................................................................................................8
9. Methodology ................................................................................................ 10
10. Responsibilities ............................................................................................ 23
11. Risk Assessments ......................................................................................... 26
1. Purpose
The purpose of this document is to outline the operation instructions that AC intends to
follow on site to operate lifting activities using Tower crane in a safe manner during
finishing all permanent structures construction in PORT SAID TUNNELS PROJECT.
2. Scope of work
This document specifies the main safety restrictions and instructions to ensure a useful and
safe operations for the tower cranes that will be used in the north cut and cover.
3. Definitions
Definition Description of Definition
Employer The Egyptian Armed Forces
Engineer SYSTRA ECG
Contractor Arab Contractors / Orascom Construction JV
Subcontractor Arab Contractors / Raimondi JV
Project Port Said Tunnels Project
PST Port Said Tunnels
PSP Project Safety Plan
4. References and Drawings.

4.1 Design Drawings
Document Number Document subject
PST-RO-CCS-DD-DR- North eastern C&C and U-section permanent structure cross
(27414 - 27415) section
PST-RO-CCS-DD-DR- North eastern C&C and U-section permanent structure
(27416 - 27419) reinforcement
PST-RO-CCS-DD-DR- North eastern C&C and U-section permanent structure Details
(27420) Cut & Cover
PST-RO-CCS-DD-DR- North eastern C&C and U-section permanent structure general
(27412) arrangement definition of typologies
PST-RO-CCS-DD-DR- North eastern C&C and U-section permanent structure Plan
(27413) view and longitudinal elevation
4.2 Construction sequence

Attached in this document Supplier operation instructions.
4.3 Others
PST-GE00-AO-000-HHSE-00002 Project Safety Plan
5. Execution Strategy
Arab contractors' success criteria are summarized as follow:
Safely fulfil its contractual scope of work.
Satisfying the employer`s requirements.
Delivering 1st class quality job in full compliance with the project specs.
6. Roles / Responsibilities
6.1 Amendment/Distribution
This method statement is subjected to update/adaptation in order to accommodate all
future issues that may arise due to site conditions during the construction phases.
The issuance of any revision shall be supervised by technical manager, construction
manager and quality manager.
Technical manager shall be responsible to prepare issue and distribute any revision to all
involved parties.
The revised method statement, if any, shall be approved by AO JV and subcontractor`s
project manager before issued for consultant approval.
6.2 Construction/implementation
* Project Manager:
Subcontractor`s project manager Mr. Amr Hamed shall be responsible for the
implementation of this method statement.
* All site personnel:
Without exception, all site personnel are responsible to ensure full compliance with this
method statement.
6.3 Roles Distribution
Name Roles
Construction Manager Shall arrange the resources and equipment required at site.
Site Engineer Shall control/direct the foreman and workforce for the operation.
Surveyor Shall verify the levels of associated work with total station and prism.
Shall execute the operation deploying the workforce and monitoring
Foreman
the performance.
Shall conduct surveillance the operation in line with approved
QA/QC documents and inspect the work prior consultant to fulfill the related
standards & project specs.
7. Constrains during work

1. Operation of the tower cranes is strictly constrained with a signed PTW that will
include all whom will be involved in this activity.
2. Calibration of tower crane after erection is a main step for assembling process
itself.
3. All work should be under supervision of safety team all the time.
4. Before erection commencing JSA should be provided and strictly followed by
personnel.
5. Ensure that operation instructions, lifting plan, risk assessment is communicated
and understood by all operatives and that all relevant checks have been performed
and that checklists are completed and signed prior to any lifting.
6. Check all communications tools before commencement of operations.
7. Full coordination between Sub and Main contractor must be provided all time.
8. Health, safety and Environment

AC will ensure its safety strategies and regulations during erection of the tower crane in a
full compliance with project specifications and safety plan.
AC`s Safety policies is concluded in the following main points:
1. ZERO ACCIDENT PHILOSOPHY:
AC believes that there is nothing more important than providing a safe and healthy environment for all
employees to complete their work activities safely regarding to the company`s main concept
People and Property are our most important corporate assets
So, AC always seeking for ZERO ACCIDENT environment which requires a deep understanding and
complete application for the following procedures:
a) Proper training, communication, consultation, planning and full co-operation with main
contractor and owner`s consultant to provide our targeted environment.
b) We shall manage any risks arising with our work activities through a reasonably practicable
control measures, JSA, STARRT, PTW and AHA.
c) We shall provide adequate resources to fulfil all HSE obligations.
d) Every employee must accept and execute their responsibility for OH&S.
e) Distribution of Method Statement & Risk assessments for any job to all involved parties.
After applying the prior procedures, you can safely start your activities.
2. Weekly Tool Box Talk:
A weekly tool box meeting will be conducted for each crew (Carpenters, welders, electricians etc.). Each
foremen will be responsible for conducting the meeting with his crew. These meetings will be kept short,
approximately 15 minutes in duration. All unsafe conditions or unsafe work practices noted on the project
which may affect the workmen will be brought to their attention. The proposed methods of eliminating
these practices or conditions will be discussed.
Employees will be encouraged to make safety suggestions in these meetings when hazardous materials
condition are about to be encountered or when crews appear to be careless in regard to safety, additional
tool box meeting be scheduled. Foremen shall submit a brief written summary of each toolbox meeting to
OH&S supervisor assigned at the zone/area.
3. Permit to work:
Work permits authorize a certain specific or general protective measures to be taken before/during work
activities commencement and as far as the work is in progress.
PTW also enforce the use of OH&S equipment. Such permits must be written and issued by competent
personnel and aims to the following:
Provide timely information to all those people who are directly or indirectly involved in the work.
Define the Safety conditions required for the workplace and the operators.
Prescribe the observance of safety regulations, which are required by AC`s OH&S.
A permit to work system shall be applied prior to any task commencement to layout the process for
achieving a safe work environment by providing management controls over the various activities that may
have hazardous interactions and to ensure that proper planning and consideration is given to potential
hazards.
Specify the exact location of the job to be dine and define of action required. Indicate all precautions taken
to provide for the safety of the operation.
PTW is to be signed and approved by authorized person to issue permits, who will be in position to be able
to guarantee the application of the safety provisions defined for the execution of the job concerned.
The work permit must always be kept by the person who is doing the job.
4. STARRT Safety task analysis and risk reduction talks
STARRT is safety awareness process assists in eliminating accidents, injuries, illness and unsafe conditions
while protecting the environment. STARRT encourages teamwork in hazard recognition and assists in
identifying safe work practices before performing each/any task by involving the task performer in a safety
task planning; STARRT encourages personal commitment and places accountability on the task performer.
STARRT is a 5 minutes pre-task briefing and must be held by first line supervisor to ensure maximum
effectiveness; STARRT should be administrated at the location where the task will be performed. New
STARRT briefing will be conducted for every new task, extended tasks and if elements or conditions change
that may impact the operation safety.
STARRT philosophy aims to:
Place pre-task planning (task steps) into workers hands
Ensure that workers are trained and fit for the assigned tasks.
Distribute job tasks/individual (responsibilities and accountabilities).
Review risk evaluation and control measures with workers.
Encourage team participation, shared learning and peer to peer observation/feedback.
Enhance worker`s ownership of safety program.
Facilitate best approach of work execution.
Emphasize success criteria.
**** The permits that will be used attached with this document.
9. Operation Instructions:
Only authorized and qualified personnel should operate the crane.
Before operating the crane check that all braking and safety systems are in good
working order.
All loads to be lifted must comply with the loading diagram of the crane.
The hoisting winch speeds must be in accordance with speed load diagram of the
hoisting winch.
Every time the crane starts to operate, an acoustical warning must be given to the
building site.
It is forbidden to pull the load at an angle or use the crane to drag loads on the ground.
Before leaving the control position , shut off control power, main power on
switchboard and do not leave load hanging
When carrying out maintenance or repair, turn main power off and make sure the
slewing brake is on.
When putting the crane in out of service conditions at the end of work or in case of
bad weather , hung hook to its upper most position, with some load hanging , hung
trolley as close as possible to the tower, release slewing brakes and clamp the base to
the rails.
10. Responsibilities:
Position Name Signature
Construction Manager Atef El Khamisey
Mechanical affairs Manager Mohammed Abd-elghany
Site Engineer Abd El-Hak El-sawy
Safety Manager Essam Arref
Safety specialist Sameh Diab

Port said tunnels under Suez canal Project (PST) Date:10-7-2017
North tunnel ( Arab Contractors Company ACC) Revision: 00A
Technical office of site preparation administration Page 21 of 31
11. Risk Assessments

Evaluation
Unmitigated
risk after
risk
Potential Hazards Recommended control Control
Activity
L S R L S R
1. Work permit *Unauthorized 2 2 4 - Work permit holder shall ensure obtaining and maintaining valid work permits. 1 2 2
commencement of - The supervisor responsible for this activity has to check the personal protective
workers may result in equipment of his staff to ensure that all required items are available and properly
exposing people and/or used.
potential to harm or - Inform all people regarding permit conditions before work starts.
danger - Supervisors must conduct weekly toolbox talk about nature of work and associated
potential hazards and their essential precautionary measures.
- All permits will be checked and verified before commencing the activity.
- Pre-job meeting shall be conducted to brief supervisors and work force on MS&RA.
2. Access and egress *Trips and falls arising 3 2 6 - All access, egress and passageways in the workplace must be kept clear of 1 2 2
from objects, articles obstructions.
obstructions and debris - Materials must be stored in designated areas away from access routes.
in access/egress routes. - Adequate lighting must be provided in case of night work.
- Workplaces should be clean and tidy at all times.
- All cabling and hosing must be neatly tied off or ramped in order to prevent tripping.
- Designated routes to be identified, materials to be stored in a safe condition.
- Use other access routes where possible.
- Provide a safe way to get to and from the work platform.
- Ensure that edge protection is installed at platform levels.
Evaluation
Unmitigated
risk after
risk
Activity Potential Hazards Recommended control Control
L S R L S R
3. Emergency *Untrained in first aid 2 3 6 - Ensure that emergency personnel are certified/trained for working into the confined 1 3 3
response and/or space (if confined space is found).
medical situation. - Ensure that at least 2 trained first aiders are present.
- Ensure to maintain free access way to the work area in order to evacuate injured
person.
- TBT for operatives on emergency response procedures, emergency evacuation
exercise.
*Unavailable equipment 2 3 6 - Ensure that rescue devices and equipment to be available all the time. 1 3 3
or devices. - Ensure to provide safe and clear passage for Emergency response team.
- Ensure fast transportation to the Main JV`s clinic
4. Manual material *Slipping, Tripping, 3 2 6 - Load weight should be checked before lifting and no employee shall be asked to loads 1 2 2
handling Falling objects above his capacity.
- If the weight of load is heavy, try to get the help from others.
- Ensure the manual load carrying access and walkways are free from obstructions.
- Train the workers on manual lifting procedures.
Evaluation
Unmitigated
risk after
risk
L S R L S R
5. Mechanical *Slipping / tripping / 2 2 4 - Employing trained and experienced persons. 1 2 2

material handling. falling of the load - Proper lifting procedures.
- Good housekeeping.
- Use of proper PPE.
- Avoid manual handling of heavy material.
- Information about the load capacity.
- Balance the load.
- Load should be properly secured.
- Size of equipment & load should be known.
- Use calibrated and certified equipment.
6. Hand and power *Injuries due to using 2 3 6 - Inspection for damage/defects to tools, cables, plugs defective tools to be taken out 1 3 3
tools. defective tools, of use immediately.
improper handling, - Proper use of PPE for all workers (gloves, hearing protection, defenders/plugs, dust
improper storage, masks).
misuse of tools, loose - Cables to be routed away from aisles and walkways where they could create trip
components and non- hazards to other persons and/or expose cables to potential damage.
use of PPE.
- Trained workers can operate power tools.
- Periodically check tools for damage/defects and where necessary take out of action
and label "do not use".
- All operatives shall be trained for proper handling tools.
- Appropriate tools only have to be used and its requirements shall be comply with site
regulations.
- Proper inspection / maintenance of tools.
- Use right tools to right jobs.
Evaluation
Unmitigated
risk after
risk
L S R L S R
7. Work during *Equipment / vehicle 2 3 6 - Enough lightings and reflective sign boards will be placed at required locations. 1 3 3
night. accidents, personnel - Flashers and revolving lights will be posted at strategic locations.
accidents, injury. - Lonely works will not be allowed during night.
- Continuous supervision will be provided for jobs.
- Area will be cordon off to avoid heavy equipment passing or stuck.
8. Lighting and *General electrical 5 4 20 - Proper Grounding for all generators (if Needed) 1 4 4
electrical works hazards. - Check all electrical panels used daily
- Outer insulation on electrical cords must be intact.
- Temporary lighting must be properly guarded and protected to avoid contact with
broken bulbs and avoid potential shocks.
- Check all electrical wires daily for defective insulation.
- Replacing defective electrical wires instead of repairing it using ordinary tapes.
- Never use Nails to hang the wires.
- Avoid using tools in wet locations
- Use switch circuit breaker and JFCI in the electrical panels
Evaluation
Unmitigated
risk after
risk
L S R L S R
9. Lifting activities *Crane Failure 2 4 8 - Supervisor shall conduct STARRT CARD before commencing the job. 1 4 4
- Ensure that crane used for lifting is inspected and with valid third party certificate.
- Make sure that operator have valid third party certificate.
- Well experienced and trained rigger/signal man shall be present.
- Operators cab must be cleared of sight obstruction.
- Load chart and crane hand signals must be posted.
- Operator must inspect thoroughly and complete equipment checklist before operating.
- Outrigger pad must be in place.
- Lifting plan shall be established in case of lifting with 2 cranes or loads more than 10
tones as well as in the case of critical lifts.
- Use tagline to control the load movement during lifting operations
*Workers underneath load 2 4 8 - Ensure an exclusion zone to be maintained at the radius of the lifting areas. 1 4 4
- Workers are not allowed at any time to be underneath the load.
*Falling of the load 2 4 8 - All lifting accessories/equipment (wires, shackles, spreader beam, etc.) shall be pre- 1 4 4
inspected and color coded before use.
- Unauthorized person must not be involved in the lifting work.
*Wind Hazards 5 2 10 - Monitor wind speed and follow the manufacturer`s recommendations. 2 2 4
- Stop all works if the wind speed exceeds the limitation by safety department.
Graphical Risk assessments for tower crane operation with recommended controls

Tower Crane Operation Manual

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Tower Crane Operation Manual

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Port said tunnels under Suez canal Project (PST) Date:10-7-2017

North tunnel ( Arab Contractors Company ACC) Revision: 00A

Project Port Said tunnels under Suez Canal.

Document Name Operation instructions for tower cranes

00A 10/7/2017 Issued For Review

4. References and Drawings.

4.2 Construction sequence

7. Constrains during work

8. Health, safety and Environment

Position Name Signature

Construction Manager Atef El Khamisey

Mechanical affairs Manager Mohammed Abd-elghany

Site Engineer Abd El-Hak El-sawy

Safety Manager Essam Arref

Safety specialist Sameh Diab

11. Risk Assessments

5. Mechanical *Slipping / tripping / 2 2 4 - Employing trained and experienced persons. 1 2 2

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